U.S. patent application number 15/611593 was filed with the patent office on 2017-09-21 for method and system for providing automated high scale fabrication of custom items.
This patent application is currently assigned to Align Technology, Inc.. The applicant listed for this patent is Align Technology, Inc.. Invention is credited to Artem Borovinskih, Maneesh Dhagat, Ivan Ionov, Vasily Ivanov, Qinghui Lu, Sergey Nikolskiy, Shiva P. Sambu, Anton Spiridonov, Dmitry Sultanov, Evgeny Timofeyev, Alexey Vishnevskiy.
Application Number | 20170270238 15/611593 |
Document ID | / |
Family ID | 39733723 |
Filed Date | 2017-09-21 |
United States Patent
Application |
20170270238 |
Kind Code |
A1 |
Borovinskih; Artem ; et
al. |
September 21, 2017 |
METHOD AND SYSTEM FOR PROVIDING AUTOMATED HIGH SCALE FABRICATION OF
CUSTOM ITEMS
Abstract
Method and system for providing volume manufacturing of
customizable items including receiving a data package including a
plurality of manufacturing parameters, each of the plurality of
manufacturing parameters associated with a unique item, verifying
the received data package, and implementing a manufacturing process
associated with the received data package is provided.
Inventors: |
Borovinskih; Artem; (Moscow,
RU) ; Lu; Qinghui; (San Jose, CA) ; Dhagat;
Maneesh; (San Jose, CA) ; Sambu; Shiva P.;
(Santa Clara, CA) ; Timofeyev; Evgeny;
(Cheboksary, RU) ; Sultanov; Dmitry; (Moscow,
RU) ; Spiridonov; Anton; (Moscow, RU) ; Ionov;
Ivan; (Moscow, RU) ; Nikolskiy; Sergey;
(Moscow, RU) ; Ivanov; Vasily; (Moscow, RU)
; Vishnevskiy; Alexey; (Moscow, RU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Align Technology, Inc. |
San Jose |
CA |
US |
|
|
Assignee: |
Align Technology, Inc.
San Jose
CA
|
Family ID: |
39733723 |
Appl. No.: |
15/611593 |
Filed: |
June 1, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13085079 |
Apr 12, 2011 |
9691110 |
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15611593 |
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11681615 |
Mar 2, 2007 |
7957824 |
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13085079 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B33Y 80/00 20141201;
G06Q 50/04 20130101; Y02P 90/30 20151101; B33Y 50/02 20141201 |
International
Class: |
G06F 19/00 20060101
G06F019/00; G06Q 50/04 20060101 G06Q050/04 |
Claims
1. A method for manufacturing a plurality of unique items on a
fabrication tray, comprising the steps of: (a) receiving, by a
processing unit, a data batch including manufacturing data
associated with a plurality of stages of a treatment profile, each
of the plurality of stages of the treatment profile corresponding
to one of the plurality of unique items; and (b) operating the
processing unit, in accordance programmed instructions, to: (1)
convert the manufacturing data of the data batch into a plurality
of object data files, each of the object data files including
three-dimensional object data associated with one of the plurality
of stages of the treatment profile; (2) generate a tray data file
based on the object data files, the tray data file including
optimized layout information representing an optimized spacing and
orientation of the plurality of unique items to be manufactured on
the fabrication tray; and (3) determine an orientation and location
on the fabrication tray for each of the plurality of unique items
in accordance with the optimized layout information and the
three-dimensional object data in each of the object data files; and
(c) manufacturing each of the plurality of unique items in its
determined orientation and location on the fabrication tray.
2. The method of claim 1, wherein the data batch further comprises
data corresponding to one or more dedicated processes for the
manufacturing of the plurality of unique items on the fabrication
tray.
3. The method of claim 1, wherein the plurality of unique items
includes a plurality of molds for dental appliances, wherein each
of the molds is manufactured in accordance with the manufacturing
data associated with one of the stages of the treatment
profile.
4. The method of claim 1, wherein the optimized layout information
further represents an optimized material usage for manufacturing
the plurality of unique items on the fabrication tray.
5. The method of claim 1, wherein the manufacturing is done by a
rapid prototyping method.
6. The method of claim 1, wherein the processing unit is further
operated to: (4) generate slice format data based on the optimized
layout information in the tray data file.
7. The method of claim 1, wherein the generation of the tray data
file comprises: (2)(A) retrieving the object data files converted
from the manufacturing data of the data batch; (2)(B) determining
the optimized spacing and orientation of the plurality of unique
items to be manufactured on the tray based on the retrieved object
data files; and (2)(C) generating the tray data file based on the
determined optimized spacing and orientation.
8. The method of claim 1, further comprising the step of: (d)
removing the manufactured items from the fabrication tray.
9. The method of claim 1, wherein the optimized spacing and
orientation provides a column-oriented layout.
10. The method of claim 9, wherein each of the unique items has a
curved segment, wherein the column-oriented layout includes a
plurality of columns of the unique items, wherein the unique items
in each column are oriented with their curved segments arranged in
a uniform direction, and wherein the unique items in adjacent
columns have their curved segments arranged in opposite
directions.
11. The method of claim 9, wherein each of the unique items has a
curved segment, wherein the column-oriented layout includes a
plurality of columns of the unique items, and wherein each column
comprises a plurality of pairs of the unique items, with the items
in each pair having curved segments arranged in opposite
directions.
12. A method for volume manufacturing of a plurality of unique
items, comprising the steps of: (a) providing a central
manufacturing processor configured to initiate a predefined
fabrication processing time period; (b) operating the central
manufacturing processor in accordance with executable program
instructions to retrieve a fabrication data package containing
manufacturing data; (c) operating the central manufacturing
processor in accordance with the executable program instructions to
verify the fabrication data package for accuracy and completeness
of the manufacturing data contained therein; (d) operating at least
one fabrication terminal to receive the verified fabrication data
package from the central manufacturing processor and to perform at
least one fabrication process in accordance with the manufacturing
data contained in the fabrication data package; (e) if the
predefined fabrication time period has not expired, repeating steps
(b) through (d); and (f) if the predefined fabrication time period
has expired, operating the central manufacturing processor in
accordance with the executable program instructions to generate a
status report.
13. The method of claim 12, wherein the fabrication data package is
retrieved via a data network.
14. The method of claim 12, wherein the fabrication data package is
retrieved from a remote terminal.
15. The method of claim 12, wherein the unique items are molds for
fabricating dental aligners, and wherein the manufacturing data
include a three-dimensional data representation of a patient's
teeth for each of a plurality of dental treatment profiles for the
patient.
16. The method of claim 15, wherein each of the treatment profiles
includes data representing each of a plurality of treatment stages,
and wherein the step of operating the central manufacturing
processor in accordance with the executable program instructions to
verify the fabrication data package for accuracy and completeness
of the manufacturing data contained therein includes verifying the
accuracy and completeness of the data representing each of the
treatment stages in each of the treatment profiles.
17. The method of claim 12, further comprising the step of
operating the central manufacturing processor in accordance with
the executable program instructions to generate a message upon
completion of the verification step.
18. The method of claim 17, wherein the fabrication data package is
retrieved from a remote terminal, and wherein the generated message
is transmitted to the remote terminal.
19. The method of claim 14, further comprising the step of
operating the central manufacturing processor in accordance with
the executable program instructions to output to the remote
terminal periodic fabrication process status update reports.
20. The method of claim 12, further comprising the step of
operating the central manufacturing processor in accordance with
the executable program instructions to generate input data for the
fabrication terminal to perform a fabrication process subsequent to
the at least one fabrication process.
21. The method of claim 12, further comprising the step of
operating the central manufacturing processor in accordance with
the executable program instructions to detect an error condition
associated with the fabrication data package, and to transmit a
report including the error condition to a remote processor.
22. The method of claim 21, wherein the remote terminal is operable
to modify the fabrication data package to address the error
condition and to communicate a modified fabrication data package to
the central manufacturing processor.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of co-pending
application Ser. No. 13/085,079 filed on Apr. 12, 2011, which is a
divisional application of application Ser. No. 11/681,615 filed on
Mar. 2, 2007, now U.S. Pat. No. 7,957,824, the disclosures of which
are incorporated herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention is related generally to the field of
manufacturing. More specifically, the present invention is related
to methods and system for providing high scale automated
manufacturing of unique items including dental aligners.
BACKGROUND
[0003] Traditional methods of dental mold making are well known,
such as those described in Graber, Orthodontics: Principle and
Practice, Second Edition, Saunders, Philadelphia, 1969, pp. 401
415. Typically, these methods involve forming an impression of the
patient's dentition using a suitable impression material, such as
alginate or polyvinylsiloxane (PVS). Impressions of the upper jaw
typically include the teeth, the palate and gingival tissue
surrounding the teeth on the facial and lingual surfaces.
Impressions of the lower jaw typically include the teeth and
gingival tissue surrounding the teeth on the facial and lingual
surfaces. Plaster is then poured into the impression to form a
relief of the dental features. The relief is a permanent,
three-dimensional mold of the dentition and oral tissues.
[0004] Improved methods of mold making include rapid prototyping.
Rapid prototyping is a technology which has developed in the last
decade. Through the use of modern solid modeling CAD packages,
combined with laser systems and new materials, solid parts may now
be generated directly from a computer model. Examples of this
technology include stereolithography (SLA), laminate object
manufacturing (LOM), and fused deposition modeling (FDM), to name a
few.
[0005] Stereolithography is a method that employs an ultraviolet
laser to cure a thin layer of liquid plastic into a solid. The
process operates by taking a thin layer of the light-sensitive
liquid plastic and passing the laser beam over the points where the
part is solid. Once a pass is completed, another layer of the
liquid is added to the existing part, and the process repeats until
the full part height is achieved. SLA parts are extremely accurate,
and tend to have excellent surface finishes. A variety of SLA
materials are available for different purposes, including waxes,
plastics, and flexible elastomers.
[0006] Laminate object manufacturing builds a part by taking
individual sheets of paper that have a layer of glue on one side
and building up successive sections of a part. As each layer is
laid down, a laser beam passes over the edges of the part,
detailing the part and separating the part from the excess
material. In addition, the laser beam creates a grid throughout the
excess material. After the final sheet is laid down, the part may
be separated from the excess material by removing cubes of the grid
in a systematic fashion. LOM parts are accurate, and very easy to
sand and paint. LOM parts also have different strengths in
different directions due to the paper layers.
[0007] Fused deposition modeling is a process that most closely
resembles a miniature glue gun. In fused deposition modeling, a
heat softening and curing plastic is melted in a small nozzle which
puts down a very fine bead wherever the solid part is supposed to
be. FDM parts have a rougher surface finish than an SLA part, but
typically are stronger and more durable. In all cases, parts
created by rapid prototyping methods are generated relatively
quickly and are accurate to a few thousandths of an inch.
[0008] Producing a dental mold with rapid prototyping methods
requires the use of a computerized model or digital data set
representing the dental geometry and tooth configuration. The model
is used to guide the mold making process to produce a replica or
relief of the computerized model. The resulting relief is a
three-dimensional mold of the dentition. This method of making
dental molds is particularly applicable to situations in which
multiple molds are needed to be produced. In this case, one
computerized model may be used to make a number of molds in an
automated fashion. In addition, this method is applicable to
situations in which a mold of a tooth arrangement which differs
from the patient's current tooth arrangement is needed to be
produced or molds of multiple tooth arrangements which differ from
each other and the patient need to be produced. In either case, the
computerized model of the patient's teeth may be manipulated to
portray each new tooth arrangement and a mold may be produced to
reflect each successive arrangement. This may be repeated any
number of times to derive a number of molds with differing tooth
arrangements. Such techniques may speed production time and reduce
costs by eliminating the need for repeated casting and artistic
resetting of teeth in traditional mold manufacturing.
[0009] Series of dental molds, such as those described above, may
be used in the generation of elastic repositioning appliances for a
new type of orthodontic treatment being developed by Align
Technology, Inc., Santa Clara, Calif., assignee of the present
application. Such appliances are generated by thermoforming a thin
sheet of elastic material over a mold of a desired tooth
arrangement to form a shell. The shell of the desired tooth
arrangement generally conforms to a patient's teeth but is slightly
out of alignment with the initial tooth configuration. Placement of
the elastic positioner over the teeth applies controlled forces in
specific locations to gradually move the teeth into the desired
configuration. Repetition of this process with successive
appliances comprising new configurations eventually moves the teeth
through a series of intermediate configurations to a final desired
configuration. A full description of an exemplary elastic polymeric
positioning appliance is described in U.S. Pat. No. 5,975,893, and
in published PCT application WO 98/58596 which designates the
United States and which is assigned to the assignee of the present
invention. Both documents are incorporated by reference for all
purposes.
[0010] To carry out such orthodontic treatment, a series of
computer models or digital data sets will be generated, stored and
utilized to fabricate a series of representative dental molds.
Typically, only the digital information related to the tooth
arrangement will be stored due to cost and space limitations.
However, to form a properly fitting elastic repositioning appliance
or other dental appliance, it will at times be necessary to include
in the mold a patient's oral soft tissue, such as a palate, facial
gingival tissue and/or lingual gingiva tissue. This may be the case
when adding accessories to a basic elastic repositioning shell,
such as palatal bars, lingual flanges, lingual pads, buccal
shields, buccinator bows or wire shields, a full description of
which is described in U.S. Provisional Patent Application No.
60/199,649 filed Apr. 25, 2000, and the full disclosure is hereby
incorporated by reference for all purposes. These accessories may
contact or interact with portions of the soft tissue requiring a
mold of such tissues to properly position the accessory in or on
the appliance. In addition, this may be the case when producing
traditional orthodontic retainers and positioners. Traditional
appliances may be used as part of an orthodontic treatment plan
utilizing elastic repositioning appliances, particularly in the
final stages of treatment. During such stages, for example, any
residual intrusion of the teeth due to the presence of elastic
appliances may be corrected with the use of a traditional retainer.
Such retainers typically comprise a polymeric replica of the palate
or portions of the gingiva which support metal wires which wrap
around the perimeter of the teeth.
[0011] Existing fabrication systems are generally run manually by
generating a report of cases and providing it into the fabrication
software. Such fabrication systems had several disadvantages.
First, each mold was not uniquely identifiable. Second, the molds
were created with problems of holes, free-floating island
structures, and unstable peninsula structures. Third, the molds
were too tall and used more resin than required. Fourth, the molds
were not packed efficiently on a tray. Fifth, laser marks were
sometimes not sharp.
[0012] Thus, a need exists to promptly process treated
three-dimensional ("3D") jaw and teeth data to create, in an
automated manner, 3D mold data for manufacturing. Also created
would be a 3D cutting path for automated cutting of aligners and 3D
placement data for automated laser marking of aligners. These are
to be achieved while minimizing resin used to build a mold,
minimizing time to build a tray of molds, maximizing automation by
reducing manual cutting of aligner, manual laser marking and
errors.
[0013] In view of the foregoing, it would be desirable to have
methods and systems to provide an automated or semi-automated
manufacturing or fabrication process for high volume and high scale
customized items such as dental aligners.
SUMMARY OF THE INVENTION
[0014] In view of the foregoing, in accordance with the various
embodiments of the present invention, there are provided methods
and system for providing high scale and high volume automated
fabrication process for customized items including, for example,
dental aligners, customized footwear, customized garment,
customized eye wear (including, for example, contact lenses, and
sunglasses), and any other customized or unique items that require
unique parameters or specification for manufacturing.
[0015] Accordingly, a method of providing volume manufacturing of
items in one embodiment of the present invention includes receiving
a data package including a plurality of manufacturing parameters,
each of the plurality of manufacturing parameters associated with a
unique item, verifying the received data package, and implementing
a manufacturing process associated with the received data
package.
[0016] These and other features and advantages of the present
invention will be understood upon consideration of the following
detailed description of the invention and the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1A is a block diagram of the overall fabrication system
for practicing the various embodiments of the present
invention;
[0018] FIG. 1B is a block diagram of the central manufacturing
terminal of the overall fabrication system of FIG. 1A in accordance
with one embodiment of the present invention;
[0019] FIG. 2 is a flowchart illustrating the automated fabrication
procedure performed by the central manufacturing terminal of the
overall fabrication system of FIG. 1A in accordance with one
embodiment of the present invention;
[0020] FIG. 3 is a flowchart illustrating the fabrication data
package retrieval procedure of FIG. 2 in accordance with one
embodiment of the present invention;
[0021] FIG. 4 is a flowchart illustrating the fabrication data
package request procedure of FIG. 3 in accordance with one
embodiment of the present invention;
[0022] FIG. 5 is a flowchart illustrating the retrieved fabrication
data package verification procedure of FIG. 2 in accordance with
one embodiment of the present invention;
[0023] FIG. 6 is a flowchart illustrating fabrication data package
processing execution by the central manufacturing terminal of FIG.
1B in accordance with one embodiment of the present invention;
[0024] FIG. 7 is a flowchart illustrating fabrication data package
processing execution by one or more fabrication terminals of FIG.
1B in accordance with one embodiment of the present invention;
[0025] FIG. 8 is a flowchart illustrating the mold object
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention;
[0026] FIG. 9 is a flowchart illustrating the tray object
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention;
[0027] FIG. 10 is a flowchart illustrating the slice format
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention;
[0028] FIG. 11 is a three-dimensional representation of a cutting
geometry profile of FIG. 8 in accordance with one embodiment of the
present invention;
[0029] FIG. 12 is a three-dimensional representation of
identification information of FIG. 8 in accordance with one
embodiment of the present invention; and
[0030] FIGS. 13A-13B are visual illustrations of a column oriented
and recursive layouts, respectively, of the optimal tray layout of
FIG. 9 in accordance with one embodiment of the present
invention.
DETAILED DESCRIPTION
[0031] FIG. 1A is a block diagram of the overall fabrication system
for practicing the various embodiments of the present invention.
Referring to FIG. 1 A, in one embodiment of the present invention,
the fabrication system 100 includes a data network 110, a remote
terminal 120 and a central manufacturing terminal 130. The central
manufacturing terminal 130 and the remote terminal 120 are each
operatively coupled to the data network 110 for bi-directional
communication. In one embodiment, the data network 110 includes one
or more of a public data network such as the internet, a private
data network including, for example, an intranet, a local area
network (LAN), a wide area network (WAN), or any other data network
that provides for secure data communication including data
encryption and the like.
[0032] Referring to FIG. 1A, the fabrication system 100 further
includes a plurality of fabrication terminals 140A, 140B, each of
which are operatively coupled to the central manufacturing terminal
130. In one embodiment, each of the plurality of fabrication
terminals 140A, 140B may be configured to perform one or more
dedicated processing to support the fabrication process.
Alternatively, the one or more of the fabrication terminals 140A,
140B may be configured to perform duplicate fabrication processing
to provide redundancy in case of failure of one or more fabrication
terminals 140A, 140B. While two fabrication terminals 140A, 140B
are shown in FIG. 1A, within the scope of the present invention,
additional fabrication terminals may be provided, each configured
to communicate with the central manufacturing terminal 130, and
further, each additional fabrication terminal configured to perform
one or more dedicated or redundant fabrication processing.
[0033] Referring yet again to FIG. 1A, the remote terminal 120 may
be configured as a personal computer, a workstation, or a server
terminal, a handheld mobile device or any other suitable device
configured to support data communication with the data network 110
and related data processing, and further, configured to communicate
with the central manufacturing terminal 130 in the fabrication
system 100. Likewise, in one embodiment, the central manufacturing
terminal 130 and each of the fabrication terminals 140A, 140B may
be configured as a personal computer, a workstation, a server
terminal, a handheld mobile device or any other suitable device
configured to support data communication and related processing in
the fabrication system 100.
[0034] For example, in one embodiment, as discussed in further
detail below, the remote terminal 120 may be configured to support
manufacturing execution system (MES) which monitors a customer
order for the customized items such as dental appliances, from the
initial order placement, through manufacturing and shipping to the
customer. In addition, the remote terminal 120 may also be
configured to support executable programs for processing and
generating appropriate fabrication related data files and formats.
More specifically, in one embodiment, the remote terminal 120 may
be configured to support and execute ClinCheck.RTM. software which,
for example, provides for electronic dental treatment plan
generation and data files (for example, the ADF file format
corresponding to three-dimensional data format for jaw and teeth
representation) associated with the manufacturing of the dental
appliances for the dental treatment.
[0035] FIG. 1B is a block diagram of the central manufacturing
terminal of the overall fabrication system of FIG. 1A in accordance
with one embodiment of the present invention. Referring to FIG. 1B,
the central manufacturing terminal 130 in one embodiment includes a
storage unit 130A, a communication interface 130B and a processing
unit 130C operatively coupled to the storage unit 130A and the
communication interface 130B.
[0036] Referring to FIG. 1B, the storage unit 130A in one
embodiment may be configured to provide persistent (nonvolatile)
storage for program and data files, and may include at least one
hard disk drive and at least one CD-ROM drive (with associated
removable media). There may also be other devices such as a floppy
disk drive and optical drives (all with their associated removable
media). In addition, the storage unit 130A may include drives of
the type with removable media cartridges, such as hard disk
cartridges and flexible disk cartridges. In one aspect of the
present invention, the processing unit 130C may be configured to
access software stored in the storage unit 130A based on and in
response to the input command or request received via the
communication interface 130B to perform corresponding associated
processing based on procedures and/or routines in accordance with
the instructions or input information received via the
communication interface 130B.
[0037] Referring again to FIG. 1B, the communication interface 130B
in one embodiment is operatively coupled to a communication link
130D for transmitting and/or receiving data including instructions
associated with the operation of the central manufacturing terminal
130. In one embodiment, the communication link 130D may include
wired or wireless communication link for bi-directional
communication with remote terminal 120 over the data network 110,
and further, with the one or more fabrication terminals 140A,
140B.
[0038] Referring back to FIG. 1A, while not shown, in one
embodiment of the present invention, each of the remote terminal
120, and the one or more fabrication terminal 140A, 140B may be
configured with one or more processing units, one or more storage
units, and one or more communication interface similar to those
respective components shown in FIG. 1B in conjunction with the
central manufacturing terminal 130, for performing the dedicated or
associated functions in conjunction with the respective data
processing and communication in the fabrication system 100.
[0039] FIG. 2 is a flowchart illustrating the automated fabrication
procedure performed by the central manufacturing terminal of the
overall fabrication system of FIG. 1A in accordance with one
embodiment of the present invention. Referring to FIG. 2, in one
embodiment, at step 210, a data processing clock of the central
manufacturing terminal 130 (FIG. 1B), for example, in the
processing unit 130C of the central manufacturing terminal 130 is
initiated. More specifically, in one embodiment, a predetermined
fabrication processing stop time, or alternatively, a predefined
fabrication processing time period (as may be defined or
pre-programmed in the central manufacturing terminal 130) is
initiated.
[0040] Referring to FIG. 2, at step 220, the fabrication data
package is retrieved from, for example, the remote terminal 120
(FIG. 1A) over the data network 110. That is, at the time of
initiating the data processing clock, the data package at the
remote terminal 120 is prepared and finalized for transmission to
the central manufacturing terminal 130. In one embodiment, the data
package may include a predefined data format such as ADF files
which provides associated three-dimensional data representation of
the jaw and teeth for each treatment profile for each patient for
purposes of manufacturing and processing of the molds including the
cutting and laser marking of the aligners. In one embodiment, the
data package is processed by manufacturing execution system
resident in the remote terminal 120 and which is configured to
monitor customer orders from the initial order placement to the
order shipment to the customer.
[0041] Referring again to FIG. 2, upon retrieving the fabrication
data package, at step 230, the retrieved fabrication data package
is verified at step 230 for accuracy to ensure, for example, that
the fabrication data package includes all data associated with each
customer order and the associated treatment profile for fabrication
processing including accuracy and completeness of all stages of
each treatment profile for fabrication processing. Upon
verification of the retrieved fabrication data package, the
fabrication processing is executed at step 240 for the retrieved
fabrication data package. Upon verification of the retrieved
fabrication data package, the central manufacturing terminal 130 in
one embodiment is configured to generate a notification message
confirming the verification of the received fabrication data
package and to transmit the notification to the remote terminal
120.
[0042] During fabrication processing, the central manufacturing
terminal 130 in one embodiment may be configured to generate a
status report and output to the remote terminal 120 to update the
remote terminal 120 on the fabrication processing status of the
retrieved fabrication data package. Periodically, at predetermined
intervals, the central manufacturing terminal 130 may be configured
to generate input data for use during the later stages in the
manufacturing line. For example, in particular embodiments, the
central manufacturing terminal 130 may be configured to generate
identification of the three-dimensional mold objects data, location
of the cutting program, and location of the laser marking data for
use during later stages in the manufacturing line.
[0043] Referring still again to FIG. 2, at step 250, it is
determined whether the data processing clock initiated at step 210
has expired. If it is determined that the data processing clock
associated with the fabrication processing has not elapsed, then
the procedure returns to step 220 to retrieve additional
fabrication data package for processing by the central
manufacturing terminal 130. More specifically, in one embodiment,
the fabrication process of the central manufacturing terminal 130
is optimized so as to utilize the processing capacity for handling
high volume manufacturing processing so as to optimize the
processing load of the central manufacturing terminal 130 and the
one or more fabrication terminals 140A, 140B. That is, as discussed
in further detail below, in one embodiment, the central
manufacturing terminal 130 is configured to monitor the status of
the fabrication data package processing, and when it is determined
that the fabrication data package processing is nearing completion
in the processing cycle, the central manufacturing terminal 130 may
be configured to prompt the remote terminal 120 to retrieve
additional fabrication data packages for manufacturing processing.
In this manner, in one embodiment, the operational status of the
one or more fabrication terminals 140A, 140B are monitored to
minimize idle time, and further to optimize the fabrication
processing load of the fabrication system 100.
[0044] Referring back to FIG. 2, if at step 250 it is determined
that the data processing clock has expired or, if it is determined
that the predefined processing time period has elapsed, the central
manufacturing terminal 130 in one embodiment is configured to
generate a status report and output to the remote terminal 120 to
update the remote terminal 120 on the fabrication processing status
of the retrieved fabrication data package. In a further embodiment,
the central manufacturing terminal 130 may be configured to archive
or backup all data or information received and/or processed by the
central manufacturing terminal 130, to generate a final input data
for use during later stages in the manufacturing line. For example,
in particular embodiments, the archived or backed up data or
information may include identification of the three-dimensional
mold objects data, location of the cutting program, or location of
the laser marking data.
[0045] In one embodiment of the present invention, the central
manufacturing terminal 130 may be configured to periodically
generate and transmit a status report or notification to the remote
terminal 120 for each of the fabrication data package retrieved and
executed for processing. More specifically, in one embodiment, the
central manufacturing terminal 130 may be configured to generate a
status notification at a predetermined time interval for each
fabrication data package in the manufacturing process, or
alternatively (or in addition to), the central manufacturing
terminal 130 may be configured to generate and transmit a status
report of the fabrication data package in manufacturing process
based on the detection of a predefined error condition associated
with the fabrication data package. In this manner, in the case
where the predefined error condition requires modification to the
data package, the error condition may be addressed at the remote
terminal 120, for example, and communicated to the central
manufacturing terminal 130 substantially contemporaneous to the
detection of the error condition so that the manufacturing process
is optimized with minimal idle or downtime.
[0046] FIG. 3 is a flowchart illustrating the fabrication data
package retrieval procedure of FIG. 2 in accordance with one
embodiment of the present invention. Referring to FIG. 3, in one
embodiment, a current active fabrication process load associated
with the retrieved fabrication data package is retrieved at step
310 by the central manufacturing terminal 130 from the remote
terminal 120. Thereafter at step 320, it is determined whether the
retrieved current active fabrication process load is less than a
predetermined active process load of the fabrication system 100
(FIG. 1A). In one embodiment, the predetermined active process load
of the fabrication system 100 may be defined or established by the
central manufacturing terminal 130 based on, for example, the
operational status of the one or more fabrication terminals 140A,
140B in the fabrication system 100.
[0047] Referring to FIG. 3, if it is determined that the current
active fabrication process load is not less that the predetermined
active process load, then the routine is timed out for a
predetermined time period at step 340, and then the routine returns
to step 310. That is, if it is determined that the fabrication
processing is at a predefined optimal manufacturing process status
based on the retrieved fabrication data package, the central
manufacturing terminal 130 in one embodiment is configured to not
request additional fabrication data package for the current or
active manufacturing cycle. On the other hand, referring again to
FIG. 3, if it is determined that the current active fabrication
process load is less than the predetermined active process load of
the fabrication system 100 for the current manufacturing cycle,
then at step 330, additional fabrication data package request is
transmitted to the remote terminal 120 (FIG. 1A) to optimize the
current manufacturing cycle processing load, and in response
thereto, the requested additional fabrication data package is
received at step 350 by the central manufacturing terminal 130.
[0048] In this manner, in one embodiment of the present invention,
the central manufacturing terminal 130 is configured to initiate
the fabrication process based on the received fabrication data
package when sufficient fabrication data package is received from
the remote terminal 120. As such, the manufacturing cycle
processing load may be optimized in one embodiment to initiate the
fabrication process when sufficient fabrication data package is
received. Indeed, the fabrication system 100 in one embodiment may
be configured to initiate the manufacturing process associated with
the fabrication data package to take advantage of the processing
volume which the fabrication system 100 is configured to
support.
[0049] FIG. 4 is a flowchart illustrating the fabrication data
package request step 330 of FIG. 3 in accordance with one
embodiment of the present invention. More specifically, referring
to FIG. 4, in one embodiment of the present invention, at step 410,
the available fabrication data package for fabrication processing
is determined. Thereafter, at step 420, it is determined whether
the available fabrication data package is less than the total
active fabrication process capacity. If it is determined that the
available fabrication data package is less than the total active
fabrication process capacity at step 420, then at step 430, all
available fabrication data package is requested for fabrication
processing. That is, in one embodiment, the central manufacturing
terminal 130 (FIG. 1B) may be configured to transmit a request to
the remote terminal 120 for all available fabrication data package
for fabrication processing by the fabrication system 100.
[0050] Referring back to FIG. 4, if at step 420 it is determined
that the available fabrication data package is not less than the
total active fabrication process capacity, then at step 440, the
available fabrication process capacity is determined to estimate,
for example, the additional fabrication data package which may be
processed in the current manufacturing cycle, and at step 450, the
incremental fabrication data package corresponding to the
determined available fabrication process capacity is requested for
concurrent processing with the active fabrication cycle.
[0051] FIG. 5 is a flowchart illustrating the retrieved fabrication
data package verification procedure of FIG. 2 in accordance with
one embodiment of the present invention. Referring to FIG. 5, the
procedure for verifying the retrieved fabrication data package in
one embodiment includes analyzing the retrieved fabrication data
package at step 510. Thereafter at step 520, it is determined if
there are any missing data in the analyzed fabrication data
package. More specifically, in one embodiment, data package
associated with each treatment profile is reviewed for any missing
treatment profile stage information. For example, for a treatment
profile including 20 stages, data package for each of the 20 stages
is reviewed to ensure that all associated data related to the 20
stages are received for the treatment profile.
[0052] If it is determined that there are missing data in the
received fabrication data package, at step 530, an associated error
notification is generated and transmitted to, for example, the
remote terminal 120 (FIG. 1A). Thereafter, at step 550, the missing
(or corrected) data package is requested at step 550. In other
words, in one embodiment, in the event that the central
manufacturing terminal 130 determines that the fabrication data
package received from the remote terminal 120 does not include all
of the data associated with the identified treatment profiles for
fabrication processing, the central manufacturing terminal 130 is
configured to identify the missing data information, and to request
the missing data from the remote terminal 120 prior to initiating
the fabrication processing of the fabrication data package.
[0053] Referring back to FIG. 5, if at step 520 it is determined
that there are no missing data in the fabrication data package
received, then at step 540 it is determined whether any of the data
in the received fabrication data package includes one or more
errors. That is, in one embodiment, the central manufacturing
terminal 130 is configured to check for the integrity of the data
in the received fabrication data package, for accuracy. If there
are not invalid or erroneous data identified in the fabrication
data package, then the routine terminates. On the other hand, if at
step 540 it is determined the received fabrication data package
includes invalid data associated with one or more stages of one or
more identified treatment profiles for fabrication processing, then
as described above, the routine returns to step 530 to generate and
transmit one or more associated error notification, and thereafter,
at step 540, a corrected data package is requested.
[0054] In the manner described above, in one embodiment of the
present invention, the central manufacturing terminal 130 may be
configured to verify the integrity of the received or retrieved
fabrication data package before the fabrication processing cycle is
initiated. Accordingly, once the fabrication processing cycle is
initiated, in one aspect, it is possible to minimize potential
disruption to the fabrication processing cycle based on erroneous
or missing data in the fabrication data package.
[0055] FIG. 6 is a flowchart illustrating fabrication data package
processing execution by the central manufacturing terminal of FIG.
1B in accordance with one embodiment of the present invention.
Referring to FIG. 6, in one embodiment, the fabrication data
package processing is executed by, for example, parsing the
fabrication data package into a predetermined number of processing
batches at step 620. Thereafter, at step 620, each of the
predetermined number of processing batches of the parsed
fabrication data package is transmitted to a corresponding one or
more fabrication terminals 140A, 140B (FIG. 1A) for processing and
execution based on the parsed fabrication data package.
[0056] For example, in one embodiment of the present invention,
each of the fabrication terminals 140A, 140B may be configured to
execute one or more dedicated processes associated with one or more
aspects of the fabrication system 100. Accordingly, the central
manufacturing terminal 130 is configured to substantially
concurrently initiate the execution of one or more processes
associated with each of the one or more parsed data packages for
each fabrication terminal 140A, 140B. In this manner, fabrication
processing by the central manufacturing terminal 130 may be divided
into sub-tasks or sub-routines and performed substantially in
parallel and concurrently to optimize the fabrication processing
cycle.
[0057] FIG. 7 is a flowchart illustrating fabrication data package
processing execution by one or more fabrication terminals of FIG.
1A in accordance with one embodiment of the present invention. More
specifically, referring to FIG. 7, at step 710 each of the
fabrication terminals 140 A, 140B in one embodiment receives a data
batch from the central manufacturing terminal 130, and at step 720,
is configured to convert each stage of the received batch data into
a corresponding three-dimensional mold object data. In one aspect,
each three-dimensional mold object data may correspond to one stage
of a plurality stages of a treatment profile of the fabrication
data package. Thereafter, a tray object data based on the mold
object data is generated at step 730, which is then converted to a
slice format data for mold cutting from the tray.
[0058] That is, in one embodiment, the one or more fabrication
terminals 140A, 140B may be configured to receive one or more batch
data from the central manufacturing terminal 130, and to convert
the received batch data into a three-dimensional mold object data
which corresponds to the received one or more batch data.
Thereafter, the one or more fabrication terminals 140A, 140B may be
further configured to generate a three-dimensional tray object data
which corresponds to an optimized layout information of the
plurality of mold data (for example, each corresponding to one
stage of the plurality of stages of the treatment profile) to
minimize material wastage and optimize the volume of mold objects
that may be provided on each mold tray prior to cutting. After
performing the optimized layout of the tray based on the mold
objects, the tray object data is converted into a polygonal format,
for example, to allow slicing of each mold from the tray.
[0059] In one embodiment of the present invention, each of the
fabrication terminal 140A, 140B may be configured to perform one or
more of the dedicated functions associated with the conversion of
each stage of the batch data into a corresponding three-dimensional
object data, the generation of the tray object data based on the
mold object data, and the conversion of the tray object data into
the slice format in the fabrication processing.
[0060] FIG. 8 is a flowchart illustrating the mold object
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention. More specifically, in one embodiment of the
present invention, the conversion of each stage of the batch data
into a corresponding three-dimensional mold object data includes
retrieving at step 810 a cutting geometry profile and an
identification information for a dental aligner associated with
each stage of the dental treatment profile in the fabrication data
package. Thereafter, a corresponding machine executable data file
is (for example, a GCode file) is generated that is associated with
the cutting geometry and identification information of each stage
of the treatment profile.
[0061] More particularly, in one embodiment, the one or more
fabrication terminal 140A, 140B is configured to generate the
machine executable data file which includes the cutting geometry
and identification information (for example, the customer
identification number, the stage of the treatment profile
information, and the like) for each dental appliance for each stage
of the treatment profile. For example, FIG. 11 illustrates a
three-dimensional representation of a cutting geometry profile, and
FIG. 12 illustrates a three-dimensional representation of
identification information of a dental appliance in accordance with
one embodiment of the present invention.
[0062] FIG. 9 is a flowchart illustrating the tray object
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention. Referring now to FIG. 9, in one embodiment,
the tray object data is generated based on the three-dimensional
mold object by, for example, retrieving all three-dimensional mold
object data in the fabrication data package in the fabrication
processing cycle at step 910, and at step 910, an optimal tray
layout is determined based on the retrieved three-dimensional mold
objects data.
[0063] For example, referring to FIGS. 13A-13B, visual
illustrations of a column oriented and recursive layouts,
respectively, of the optimal tray layout are shown in accordance
with one embodiment of the present invention. Indeed, in one
embodiment of the present invention, the optimal tray layout in one
embodiment is determined based on the retrieved three-dimensional
mold objects data so as to optimize the spacing and material usage
of each dental appliance associated with each stage of each
treatment profile associated with the fabrication data package.
[0064] Referring back to FIG. 9, upon determination of the optimal
tray layout, the tray object file is generated based on the
optimized layout information. For example, in FIG. 13A, a
three-dimensional column oriented layout of the mold objects are
shown in one embodiment, while in FIG. 13B, a three-dimensional
recursive layout of the mold objects for batch processing is shown.
In this manner, in one embodiment of the present invention, the
adjacent columns as shown in FIGS. 13A, 13B are oriented in
opposite direction to optimize the tray layout. In one aspect, the
tray layout optimization may include a first column layout format
that orients the mold objects equally such that the curved segment
of the mold object is configured to fit into the opening segment of
another mold object (as depicted in the three-dimensional
illustration of the tray layout shown in FIGS. 13A, 13B, for
example). Alternatively, in a further embodiment, column
orientation including an interlocked pair configuration for mold
objects may be used such that mold objects are oriented in opposite
direction and placed at a predetermined angle. More specifically,
in one aspect, the recursive layout as shown in FIG. 13B including
a segment of the tray layout rotated by approximately 90 degrees
may be used to obtain an optimized tray layout configuration.
[0065] FIG. 10 is a flowchart illustrating the slice format
generation procedure of FIG. 7 in accordance with one embodiment of
the present invention. Referring to FIG. 10, in one embodiment, the
slice format generation procedure includes determining an
identifier associated with the tray object at step 1010, and then
retrieving geometry profile of the dental appliance such as
aligners associated with the mold object in the corresponding tray
object at step 1020. Thereafter, at step 1030, one or more
fabrication instructions associated with the tray object is
generated so as to be executed by the one or more manufacturing
machines executing the manufacturing processes associated with the
fabrication of the dental appliances corresponding to the
fabrication data package.
[0066] For example, in one embodiment, for each tray object, the
corresponding mold geometries are retrieved and a layout
transformation procedure is implemented and converted into the
manufacturing machine executable file format such that the mold
slicing procedure may be performed for each mold object associated
with the one or more tray objects for the treatment profiles
associated with the fabrication data package.
[0067] In this manner, in particular embodiments, methods and
systems are provided for automated or semi-automated manufacturing
or fabrication process for high volume and high scale customized
items such as dental aligners. More particularly, in accordance
with one or more embodiments, there is provided method and system
to promptly process treated three-dimensional ("3D") jaw and teeth
data to generate, in an automated manner, 3D mold data for
manufacturing. In addition, a 3D cutting path may be generated for
automated cutting of aligners, and 3D placement data for automated
laser marking of aligners, while minimizing resin used to build a
mold, minimizing time to build a tray of molds, maximizing
automation by reducing manual cutting of aligner, manual laser
marking and errors. Accordingly, in particular embodiments, each
mold may be uniquely identifiable, generated substantially free of
holes, free-floating island structures, or unstable peninsula
structures, configured to efficiently use the required resin, and
where the molds may be packed efficiently on a tray, and also,
laser marks are sufficiently sharp.
[0068] As discussed above, in accordance with the various
embodiments of the present invention, there are provided method and
system for automated fabrication process for high volume customized
items where each item includes parameters or configurations that
are unique to the particular item. While the description above in
provided in conjunction with dental appliances, within the scope of
the present invention, the automated fabrication processing may be
implemented for the manufacturing of any high volume customized
items including, for example, customized footwear each configured
to fit a unique customer's feet dimensions, customized apparel,
customized eyewear, or any other customized consumable or other
goods where mass, high volume production generally requires
customized tooling requirements for the manufacturing machines.
[0069] A method of providing volume manufacturing of items in
accordance with one embodiment of the present invention includes
receiving a data package including a plurality of manufacturing
parameters, each of the plurality of manufacturing parameters
associated with a unique item, verifying the received data package,
and implementing a manufacturing process associated with the
received data package. The method in one aspect may further include
generating one or more notification associated the data
package.
[0070] Moreover, in a further aspect, receiving the data package
may include determining a current active processing capacity based
on the received data package, and retrieving additional data
package for implementation of the manufacturing process
substantially concurrently with the received data package, where
the additional data package may be retrieved when the current
active processing capacity is not optimized based on the received
data package.
[0071] Moreover, verifying the received data package in a further
aspect may include detecting an error condition associated with one
or more of the plurality of manufacturing parameters, and
generating an error notification associated with the detected error
condition, where generating error notification in one embodiment
may include requesting an updated data package, and receiving an
updated data package without the detected error condition.
[0072] The detected error condition may include one or more of a
missing data, or an invalid data of the data package.
[0073] Moreover, in a further aspect, implementing the
manufacturing process may include parsing the verified data
package, and generating one or more object files based on the
parsed data package, each of the one or more object files
associated with a corresponding one or more manufacturing routine,
where one or more manufacturing routine may be a dedicated routine
associated with the manufacturing process, and further, where the
dedicated routine may include one of a three-dimensional data
generation associated with the unique item, or a three-dimensional
data generation associated with a physical layout of the unique
item.
[0074] In still another aspect, each of the one or more
manufacturing routine may be executed substantially
concurrently.
[0075] The unique item in one aspect includes a dental appliance,
where the dental appliance may include a dental aligner.
[0076] A method of providing high volume manufacturing process in
accordance with another embodiment of the present invention
includes receiving a batch data associated with the manufacturing
of a plurality of unique items, and generating one or more object
files associated with each of the plurality of unique items. In a
further aspect, the batch data may be associated with one or more
dedicated processes for the manufacturing of the plurality of
unique items.
[0077] Additionally, the one or more object files may include one
or more three-dimensional object data, each associated with the one
or more of the plurality of unique items, where the one or more
three-dimensional object data may include one or more of a geometry
parameter, an identification parameter, or a layout parameter.
[0078] A system for high volume manufacturing of customized items
in accordance with still another embodiment includes a remote
terminal, and a storage unit, a controller unit operatively coupled
to the storage unit, and configured to receive from the remote
terminal, a data package including a plurality of manufacturing
parameters, each of the plurality of manufacturing parameters
associated with a unique item, the controller unit further
configured to verify the received data package and to implement a
manufacturing process associated with the received data
package.
[0079] The controller unit may be further configured to transmit
one or more notification associated the data package to the remote
terminal.
[0080] In a further aspect, the controller unit may also be
configured to determine a current active processing capacity based
on the received data package, and to retrieve additional data
package from the remote terminal for implementation of the
manufacturing process substantially concurrently with the received
data package, where the controller unit may be configured to
retrieve the additional data package from the remote terminal when
the current active processing capacity is not optimized based on
the received data package.
[0081] In another aspect, the controller unit may be further
configured to detect an error condition associated with one or more
of the plurality of manufacturing parameters, and to transmit an
error notification associated with the detected error condition to
the remote terminal, where the controller unit may additionally be
configured to request an updated data package from the remote
terminal, and to receive an updated data package from the remote
terminal without the detected error condition.
[0082] In another aspect, the system may further include a
fabrication terminal operatively coupled to the controller unit,
the fabrication terminal configured to receive the verified data
package, to parse the verified data package, and to generate one or
more object files based on the parsed data package, each of the one
or more object files associated with a corresponding one or more
manufacturing routine, where each of the one or more manufacturing
routine may be a dedicated routine associated with the
manufacturing process.
[0083] Moreover, the dedicated routine may include one of a
three-dimensional data generation associated with the unique item,
or a three-dimensional data generation associated with a physical
layout of the unique item.
[0084] The various processes described above including the
processes performed by the central manufacturing terminal 130, the
remote terminal 120, and fabrication terminals 140A, 140B (FIG. 1A)
in the software application execution environment in the
fabrication system 100 including the processes and routines
described in conjunction with the Figures may be embodied as
computer programs developed using an object oriented language that
allows the modeling of complex systems with modular objects to
create abstractions that are representative of real world, physical
objects and their interrelationships. The software required to
carry out the inventive process, which may be stored in the memory
or data storage unit 130A of the central manufacturing terminal 130
(and/or other equivalent storage units of the respective one or
more remote terminal 120 and fabrication terminals 140A, 140B, may
be developed by a person of ordinary skill in the art and may
include one or more computer program products.
[0085] Various other modifications and alterations in the structure
and method of operation of this invention will be apparent to those
skilled in the art without departing from the scope and spirit of
the invention. Although the invention has been described in
connection with specific preferred embodiments, it should be
understood that the invention as claimed should not be unduly
limited to such specific embodiments. It is intended that the
following claims define the scope of the present invention and that
structures and methods within the scope of these claims and their
equivalents be covered thereby.
* * * * *